Mattress or pillow construction

ABSTRACT

A mattress or pillow for hospital use generally consisting of a core of parallel-epipedic shape formed of elastic plastic having open cells, a layer of elastic plastic having open cells secured by heat-lamination to said core but having a shorter solidification time than the core. Said construction then being entirely covered by a protective film formed of a plastic which is heat-laminated to the layer of elastic plastic and which is easy to clean and disinfect.

The present invention relates to a product, preferably a mattress, pillow or the like, of elastic plastic material having predominantly open cells. The plastic may be a polyether or a cold-foamed polyether known as cold foam. A plastic according to the present invention is described in the following material specification, for instance. The product primarily concerned here is a pillow or mattress. Such a product is manufactured in parallel-epipedic form. When such a pillow or mattress is to be used in nursing care it is advisable for it to be provided with a casing which entirely or partially covers the product. The casing is generally permanently fixed to the mattress or pillow, preferably by means of heat-lamination. The casing generally consists of a plastic having the nature of a foil or film. The plastic shall be of a type enabling the pillow or mattress provided therewith to be easily disinfected and cleaned from dirt particles without it being necessary to change the casing is. The casing suitably formed from a polyurethane. A casing suitable for the present invention is described in the following material specification. When a pillow or mattress of the type described above is to be provided with a casing by means of heat-lamination, it has been found that the plastic in the product itself requires approximately 24 hours for curing and this is far too long a time to permit economical factory manufacture of pillows and mattresses with protective casings.

The object of the present invention is to eliminate said long manufacturing time, reducing the time so that the product can continue to another stage of manufacture immediately. This is achieved by arranging a layer of elastic plastic having predominantly open cells between the casing and the product, said plastic being of a type requiring a considerably shorter curing time than the plastic in the product itself. The plastic preferably consists of a polyester. A plastic in accordance with the present invention, which is suitable for the layer, is described in the following material specification. A suitable layer thickness is 1.42-4 mm.

The present invention will be further described with reference to the accompanying drawing showing a perspective view of a mattress according to the present invention.

1 is a parallel-epipedic body which is intended to constitute the core of a mattress. The body is manufactured from polyether and is provided with open cells. The physical properties of the care body are mentioned in the two examples, Tables I and II. A layer 2 of an elastic plastic having predominantly open cells is arranged around the body. The physical properties of this plastic are revealed in Table V. The inside of the layer is heated prior to application. After application, the outer surface of the layer is also heated, after which a plastic film or foil 3 is applied on the layer 2. The finished mattress requires a curing time of about 2 hours before the heated surfaces have solidified. The outer layer or foil 3 has physical properties which are described in Tables III and IV. The use of an intermediate layer of elastic plastic with open cells enables the manufacturing time to be reduced to less than one tenth and satisfactory adhesion is obtained between the various layers despite the intermediate layer consisting of an elastic plastic with open cells.

                  TABLE I                                                          ______________________________________                                         MATERIAL SPECIFICATION RELATING TO CORE BODY                                   Example 1                                                                      ______________________________________                                         Quality             F30                                                        Color               Grey                                                       Standard Width      2000 mm                                                    Total Height        1040 mm +/-3%                                              Shoulder Height     880 mm +/-3%                                               Bulk Density        Gr. pr. kg/m.sup.3 +/-5%                                   ISO 1855/SIS 169209/DIN 53420                                                                      Net pr. kg/m.sup.3 +/-5%                                                       27                                                         Hardness Indes (50 mm)                                                                             150 N+/-4%                                                 ISO 2439/SIS 169212/DIN 53576                                                  Dynamic Fatique     50 N                                                       ISO 3385/SIS 169214/DIN 53574                                                                      3.0%                                                       Height Loss                                                                    Elongation          240%                                                       ISO 1798/SIS 169211/DIN 53571                                                                      100 kPa                                                    Elongation at break                                                            Deformation         4.0%                                                       ISO 1856/SIS 169213/DIN 53572                                                  Elasticity          46%                                                        SIS 169217                                                                     Impact Strength     3.3 kPa +/-6%                                              ISO 3386/DIN 53577                                                             Field of Application                                                                               LAMINATION                                                 Comments                                                                       Fulfills requirements for FMVSS 302/1972 pt. 4.3 - laminatable                 ______________________________________                                    

                  TABLE II                                                         ______________________________________                                         Example 2                                                                      ______________________________________                                         Quality             HE37                                                       Color               White                                                      Standard Width      2000 mm                                                    Total Height        860 mm +/-3%                                               Shoulder Height     700 mm +/-3%                                               Bulk Density        Gr. pr. kg/M.sup.3 +/-4%                                                       38                                                         ISO 1855/SIS 169209/DIN 53420                                                                      Net pr. kg/m.sup.3 +/-4%                                                       36                                                         Hardness Index (50 mm)                                                                             150 N +/-4%                                                ISO 2439/SIS 169212/DIN 53576                                                  Dynamic Fatigue     30 N                                                       Height Loss         1.5%                                                       ISO 3385/SIS 169212/DIN 53574                                                  Elongation          220%                                                       ISO 1798/SIS 169211/DIN 53571                                                                      110 kPa                                                    Elongation at Break                                                            Deformation         2.0%                                                       ISO 1856/SIS 169213/DIN 53572                                                  Elasticity          58%                                                        SIS 169217                                                                     Impact Strength     3.6 kPa +/-6%                                              SO 3386/DIN 53577                                                              Field of Application                                                           Cushions, Office and Dining-room Furniture, Mattresses                         Comments                                                                       Fulfills requirements for Bulletin 117 sec. A & D                              STATE OF CALIFORNIA.                                                           Mattress 90 nm in thickness fulfilled the highest requirements                 for furniture.                                                                 ______________________________________                                    

                                      TABLE III                                    __________________________________________________________________________     Material specification relating to casing                                      Example 1                                                                      Physical properties                                                                                      TF-310-312-330-800                                                                         TF-410                                                     Standard                                                                               Polyester   Polyether                                Test              ASTM    1 Mil 3-5 Mil                                                                              1 Mil 3-5 Mil                            __________________________________________________________________________     Specific Gravity  D-792   1.22  1.22  1.14  1.14                               Hardness Shore, A D-2240  93(50D)                                                                              93(50D)                                                                              82    82                                 Stress-Strain     D-883                                                        Ultimate Strength psi(MPA)                                                                            MD*                                                                               9000(62.1)                                                                           8500(58.7)                                                                           6000(41.4)                                                                           6500(44.8)                                                TD*                                                                               5000(34.5)                                                                           8100(55.9)                                                                           3000(20.7)                                                                           5200(35.9)                         100% Modulus, psi(MPA) MD 3000(20.7)                                                                           1600(11.4)                                                                           1700(11.7)                                                                           800(5.5)                                                  TD 1100(7.6)                                                                            1600(11.0)                                                                           530(3.7)                                                                             660(4.6)                           300% Modulus, psi(MPA) MD       4900(33.8)  1500(10.3)                                                TD       4800(33.1)  1100(7.6)                          Elongation at Break, % MD 200   410   350   570                                                       TD 400   410   650   630                                Tear initiation, Graves, lb/in(kg/cm)                                                            D-1004                                                                              MD 250(44.8)                                                                            500(107.4)                                                                           250(44.8)                                                                            430(77.0)                                                 TD 500(89.5)                                                                            560(100.2)                                                                           380(68.0)                                                                            420(75.2)                          Tear Propagation, lb/in(kg/cm)                                                                   D-1938                                                                              MD 250(46.5)                                                                            500(89.5)                                                                            260(46.5)                                                                            212(37.9)                                                 TD 400(71.6)                                                                            560(100.2)                                                                           250(44.8)                                                                            272(48.7)                          Moisture Vapor Transmission,                                                                     E-95-E  46    23    76    43                                 gm/24 hr/100 sq. in.                                                           Abrasion Resistance, Taber CS-17                                                                         3      3    8                                        5000 Cycles; 1,000 gm load; 75 mil    (1000 cycles)                            sample; mg lost Taber                                                          Impact Strength lb/in(kg/cm)                                                                     D-1709  400(71.7)                                                                            400(71.7)                                                                            390(69.9)                                Permeation Properties                                                          Gas transmission rate,                                                                           D-1434                                                       cc/24 hr/100 sq. in.                                                           Oxygen                    75    72    1000  542                                Nitrogen                  45    18    450   151                                Carbon Dioxide            450   729   4300  6902                               Air                       55    28    NA    214                                Helium                    NA    349   NA    1188                               MVT gm/mil/24 hr/100 sq. in.                                                                     E-96-E  8.6         1.86                                     Thermal Properties (.075" sample)                                                                D-746   -80(-62)    -100(-73)                                Solenoid Brittle pt. °F.(°C.)                                    Masland Cold Crack, °F.(°C.)                                                       D-1790  -100(-73)   -100(-73)                                Gehman Stiffness Modulus,                                                                        D-1053                                                       psi(mpa)                                                                       @ Room Temp.              1700(11.7)  570(4.1)                                 @ 32° F.(0° C.)                                                                            2800(19.3)  750(5.2)                                 @ 0° F.(-17.8° C.)                                                                         17500(120.7)                                                                               1000(6.9)                                @ -40° F.(-40° C.)                                                                         --          5900(40.7)                               Heat Seal Range                                                                °F.                350-400     350-400                                  °C.                176-204     176-204                                  __________________________________________________________________________      N.A. Data not available                                                  

                  TABLE IV                                                         ______________________________________                                         Immersion data                                                                 28 days @ 23° C. (73° F.)5 mil film                              Test--   Ultimate Tensile                                                                           Tensile Change                                                                             Ultimate Elong                                Base     psi         (%)         (%)                                           Material--                                                                              Ester   Ether   Ester Ether Ester  Ether                              ______________________________________                                         Original 8500    5400    --    --    410   570                                 ASTM     7900    6500    -71     0   405   610                                 Fuel A                                                                         ASTM     6200    4300    -27   -34   460   150                                 Fuel B                                                                         ASTM     7000    3800    -17   -42   510   590                                 Fuel C                                                                         ASTM Oil 8100    NA      -6    NA    380   NA                                  Type 1                                                                         ASTM Oil 6700    6850    -21   +4.6  390   590                                 Type 2                                                                         ASTM Oil 7400    3900    -13   -40   430   540                                 Type 3                                                                         Perchloro-                                                                              6500    3000    -24   -54   420   510                                 ethylene                                                                       Trichloro-                                                                              4800    2000    -44   -69   460   420                                 ethylene                                                                       Benzene  5500    3300    -35   -49   500   670                                 MEK      3600    *       -58   *     550   *                                   Isopropyl                                                                               5300     300    -38   -95   510   670                                 Alcohol                                                                        Saturated                                                                               7500    5300    -12   -18   410   560                                 NaCl                                                                           Ethylene 6800    5650    -20   -13   420   650                                 Glycol                                                                         20% NaOH *       4800    *     -26   *     620                                 20% H.sub.2 50.sub.4                                                                    6600    2500    -22   -26   465   450                                 50% Formic                                                                              *       2600    *     -60   *     680                                 Acid                                                                           Synthetic                                                                               7300    5200    -14   -20   400   585                                 Perspiration                                                                   H.sub.2 O @ 70° C.                                                               3500    5200    -59   -20   450   680                                 (158° F.)                                                               95% RH @ 1400    3700    -83   -43   170   620                                 70° C.(150°  F.)                                                 ______________________________________                                         Immersion data                                                                 28 days @ 23° C. (73° F.) 5 mil film                             Test--   Elong Change                                                                               Volume Change                                                                              Weight Change                                 Base     (%)         (%)         (%)                                           Material--                                                                              Ester   Ether   Ester Ether Ester Ether                               ______________________________________                                         Original --      --      --    --    --    --                                  ASTM     -1.2    +7.0    +1.7  +4.7  -0.1  +2.1                                Fuel A                                                                         ASTM     +12     +7.0    +8.7  +18   +8.3  +16                                 Fuel B                                                                         ASTM     +24     +3.5    +10   +34   +9    +30                                 Fuel C                                                                         ASTM Oil -7      NA      +13   NA    +1.5  --                                  Type 1                                                                         ASTM Oil -4.9    +3.5    +0.3  + 5.0 +.4   +4.5                                Type 2                                                                         ASTM Oil +4.9    -5.3    +3.2  +11   +2.4  +10                                 Type 3                                                                         Perchloro-                                                                              +15     -10.5   +20   +73   +22   +94                                 ethylene                                                                       Trichloro-                                                                              +12     -26     +54   +242  +51   +270                                ethylene                                                                       Benzene  +22     +17     +38   +108  +30   +95                                 MEK      +34     *       *     +30   *     +27                                 Isopropyl                                                                               +24     +17     +11   +34   +9    +26                                 Alcohol                                                                        Saturated                                                                                 0     -1.8    -0.7  NA    -0.6  --                                  NaCl                                                                           Ethylene +2.4    +14     +4    +4    +4    +4                                  Glycol                                                                         20% NaOH *       +8.8    -27   +5    -27   +6                                  20% H.sub.2 50.sub.4                                                                    13.4    -2.1    +0.7  +1.4  +1.2  +2.1                                50% Formic                                                                              *       +19     *     -17   --    +6                                  Acid                                                                           Synthetic                                                                               +2.4    +2.6    +2.3  *     --    +1.3                                Perspiration                                                                   H.sub.2 O @ 70° C.                                                               +9.8    +19     +0.4  NA    +1.6  NA                                  (158° F.)                                                               95% RH @ - 59    +8.7    --    --    --    --                                  70° C.(150° F.)                                                  ______________________________________                                         Physical Properties                                                            Flame Retardant                                                                Polyether Base Material                                                                                     ASTM                                                                 Typical   Test                                                                 Properties                                                                               Procedure                                         ______________________________________                                         UL Vertical 94 Flame Test                                                                         V O       --                                                Tensile, psi       4700      D412                                              100% Modulus, psi  850       --                                                300% Modulus, psi  1350      --                                                Elongation, %      570       --                                                Graves Tear, pli   370       D624                                              Crescent Tear, pli 460       D624                                              Hardness, A-C-D    87-58-41  D2240                                             Taber Abrasion, mgm loss, CS-17                                                                   6.2       --                                                wheel, 1000 gm, 1000 cycles                                                    Vicat B, °C.                                                                               94        D1525                                             Brittleness Temp   -70° C.                                                                           D746                                              Gehman RT Modulus  1250      D1053                                             T.sub.2            -15° C.                                                                           --                                                T.sub.5            -31° C.                                                                           --                                                T.sub.10           -37° C.                                                                           --                                                T.sub.50           -51° C.                                                                           --                                                T.sub.100          --        --                                                Freeze Point       -51° C.                                                                           --                                                Compression Set,   23%       D395                                              22 hours, RT                                                                   Compression Set,   66%       --                                                22 hours, 70° C.                                                        Specific Gravity   1.226     --                                                ______________________________________                                          *sample dissolved                                                              NA -- Data not available                                                 

                  TABLE V                                                          ______________________________________                                         Material specification concerning intermediate layer.                          PRODUCT DESCRIPTION                                                            For types 2130170 and 2333170                                                                 2130170                                                                               2333170                                                  ______________________________________                                         Weight of sample 28.0     31.0                                                 SIS 169209                                                                     kg/m.sup.3 ± 6%                                                             Hardness index   170      170                                                  SIS 169212                                                                     N ± 16%                                                                     Ultimate strength                                                                               231      246                                                  SIS 169211                                                                     kPa, typical value                                                             Elongation at break                                                                             240      235                                                  SIS 169211                                                                     %, typical value                                                               Tear strength    6.9      6.7                                                  ASTM D 1564                                                                    N/cm, typical value                                                            Deformation      7        9                                                    SIS 169213                                                                     (75%, 70° C., 22 h)                                                     %, typical value                                                               Flame retardant  --       MVSS 302                                             standard                                                                       ______________________________________                                          There is no entirely satisfactory exactitude with respect to the               distribution of open and closed cells. The ratio also tended to vary           somewhat from production to production.                                        However, it can be assumed that polyether foam normally has a proportion       of open cells in excess of 95% whereas polyester foam normally tends to        have a proportion of more than 80%.                                            Typically it can be assumed that polyester foam (with respect to the type      described) has about 90% open cells but, as mentioned, with slight             variation from production to production.                                  

I claim:
 1. A mattress, pillow, or the like, having a core formed of an elastic plastic material having a predominant portion of open cells, a thin layer of soft elastic plastic polyester material having predominately open cells and a short curing time said plastic thin layer completely covering said core and being permanently joined to said core by means of heat-lamination and necessitating minimum solidification time, a polyurethane plastic film which is easy to disinfect and clean, entirely covering and permanently fixed by heat-lamination to said thin layer of soft elastic plastic.
 2. A mattress, pillow, or the like as defined in claim 1 wherein said thin layer of soft elastic plastic has a thickness of from 1.42 to 4 mm. 